One of the largest mattress manufacturers in the U.S. will be tucking into a new manufacturing and distribution plant in Lewisville. Dallas-based developer Billingsley Co. has signed Sherwood Bedding—a Tempur Sealy company—to a 10-year lease for the customized, 234,395-square-foot facility to be built near the Grandscape complex west of the North Dallas Tollway.

Construction is slated to begin in February 2022, with an estimated completion date of March 2023.

Based in Florida, Sherwood is a low-cost producer of private label and OEM mattresses for third-party retailers. 

“Sherwood bedding has been a longstanding tenant of ours at another location and their robust pace of growth required that they move to a larger building.” said George Billingsley, partner at Billingsley Company, in a statement. “We’re honored to retain the relationship and partner with them on this build to suit development. With the strong market demand, we look forward to commencing on other new industrial developments in both Lewisville and Denton in the near future.”

The new plant will be located near the intersection of Plano Parkway and Tittle Drive in Billingsley’s Austin Ranch development.

Damian Rivera of ESRP represented Sherwood in the deal; George Billingsley represented Billingsley Company. Gordan Highlander will be the general contractor for both the shell building and the tenant finish out.

According to the developer, Sherwood will manufacture out of the new facility and expects to bring “many jobs” to the city of Lewisville and Denton County.

Rendering of Sherwood Bedding’s new warehouse in the Austin Ranch development [Image: Billingsley Company]

Tempur Sealy acquired Sherwood for $40M in 2020

Tempur Sealy acquired Sherwood Bedding in January 2020 by purchasing an 80% stake in the company worth around $40 million. At the time, Sherwood estimated its annual wholesale revenues at more than $150 million.

The Ellman Family, third-generation founders of Sherwood, retained 20% ownership interest. You can see a video about their company’s story here.   

‘Handmade craftsmanship meets advanced automation’

One way Sherwood achieves lower cost production is through advanced automation. 

“We believe equipping the industry’s most talented craftsmen with leading edge technology is the best way to deliver superior quality products at a lower price,” the company says on its website. 

“While we still believe in overseeing our own quilting, sewing, and foam cutting by hand, we have also learned to use automation in areas where it makes the most sense and to increase accuracy. This enables us to consistently produce higher quality products at production costs that are lower than our competitors,” the company adds.

Sherwood already has four regional factories across the U.S.

Intellibed Gel Matrix technology [Photo: Intellibed]

Working with ‘exclusive Gel Matrix technology’

One company Sherwood manufactures mattresses for is Salt Lake City-based Intellibed, using a key Intellibed technology—Gel Matrix, a flexible, rubberlike, honeycomb-shaped grid that provides a layer of both comfort and support.

According to Intellibed, Gel Matrix is up to three times firmer than memory foam, offering superior pressure relief thanks to its buckling properties. It’s based on tech that was originally developed by NASA to enable astronauts to sleep during space flights.

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